Прокладка Головки Блока Цилиндров Установка. Corolla Auris

Set the crankshaft pulley bolt to the crankshaft.

Check the piston protrusions for each cylinder.

1. Clean the cylinder block with solvent.
   

2. Set the piston of the cylinder to be measured to slightly before TDC.
   





3. Place a dial indicator on the cylinder block, and set the measuring tip as shown in the illustration.
   

4. Set the dial indicator at 0 mm (0 in.).
   

   УКАЗАНИЕ:

   Make sure that the measuring tip is flat against the cylinder block gasket surface and piston head when taking the measurements.

5. Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.
   

6. Measure the piston protrusion value of each cylinder at 2 places as shown in the illustration, making a total of 8 measurements.
   

   Standard piston protrusion:

   0.300 to 0.560 mm (0.0118 to 0.0221 in.)
   

   If the protrusion is not as specified, remove and reinstall the piston and connecting rod.
   

7. Select the size of a new cylinder head gasket based on the largest piston protrusion value of the 8 measurements.
   

Select a new cylinder head gasket.

УКАЗАНИЕ:

Cylinder head gaskets are marked A, B, C, D or E accordingly.

Cylinder head gasket thickness:

Cutout mark	Specified Condition
A	1.00 to 1.10 mm (0.0394 to 0.0433 in.)
B	1.05 to 1.15 mm (0.0413 to 0.0453 in.)
C	1.10 to 1.20 mm (0.0433 to 0.0472 in.)
D	1.15 to 1.25 mm (0.0453 to 0.0492 in.)
E	1.20 to 1.30 mm (0.0472 to 0.0512 in.)

1. Select the largest piston protrusion value from the measurements and then select a new appropriate gasket according to the table below.
   

   Piston protrusion:

   Gasket size	Specified Condition
   Use A	0.300 to 0.355 mm (0.0118 to 0.0140 in.)
   Use B	0.355 to 0.405 mm (0.0140 to 0.0159 in.)
   Use C	0.405 to 0.455 mm (0.0159 to 0.0179 in.)
   Use D	0.455 to 0.505 mm (0.0179 to 0.0199 in.)
   Use E	0.505 to 0.560 mm (0.0199 to 0.0221 in.)

Set the crankshaft to the following conditions by turning the crankshaft pulley bolt.

1. The No. 1 piston is set to approximately 90° ATDC/compression.
   

2. The key is set to the position shown in the illustration.
   

Place the cylinder head gasket in position on the cylinder block.

ПРИМЕЧАНИЕ:

Be careful of the installation direction.

Place the cylinder head on the cylinder block.

Apply a light coat of engine oil to the following: 1) the threads of the cylinder head bolts, 2) under the heads of the cylinder head bolts, and 3) the washers.

Install the cylinder head bolts.

УКАЗАНИЕ:

1. For new bolts, perform steps 1 to 3. For used bolts, perform only step 1.
   
2. If any bolt is broken or deformed, replace it.
   

Step 1:

1. Install and uniformly tighten the 10 cylinder head bolts, in several steps in the sequence shown in the illustration.
   

   Момент затяжки:

   50 Н*м{510 кгс*см, 37 фунт-сила-футов}

   УКАЗАНИЕ:

   If the cylinder head bolt does not meet the torque specification, replace the cylinder head bolt.

2. Mark the front of the cylinder head bolts with paint.
   

3. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
   

4. Perform the step above twice.
   

5. Check that the paint marks are positioned as shown in the illustration.
   

Step 2:

1. Loosen the cylinder head bolts by 90° in the sequence shown in the illustration.
   

2. Perform the step above again.
   

3. Check that the paint marks are positioned as shown in the illustration.
   

Step 3:

1. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
   

2. Perform the step above twice.
   

3. Check that the paint marks are positioned as shown in the illustration.
   

Be sure to inspect the valve lash adjuster before installing it (see page Нажмите здесь).

Install the 16 lash adjusters.

ПРИМЕЧАНИЕ:

Install the lash adjusters to their original positions.

Set the 16 rocker arms to the 16 lash adjusters.

ПРИМЕЧАНИЕ:

Before and after setting the No. 1 camshaft and No. 2 camshaft, firmly set the rocker arms to the lash adjusters.

Install the No. 2 bearing cap.

Apply clean engine oil to the cam of each camshaft, journals of the cylinder head and the rollers of the valve rocker arms.

Place the No. 2 camshaft on the cylinder head as shown in the illustration so that the No. 1 and No. 3 cylinder cam lobes face upward.

ПРИМЕЧАНИЕ:

Before and after setting the No. 1 camshaft and No. 2 camshaft, check that the rocker arms are firmly set to the lash adjusters.

Align the No. 1 camshaft and No. 2 camshaft timing marks (1 dot mark each).

Place the No. 1 camshaft on the cylinder head.

Set the No. 1 camshaft bearing cap on the cylinder head.

Set the No. 3 camshaft bearing caps on the cylinder head as shown in the illustration.

УКАЗАНИЕ:

Confirm the marks and numbers on the camshaft bearing caps and place them each in the proper position and direction.

Set the oil delivery pipes, bolts and union bolts.

Temporarily install the 2 union bolts.

Install the bearing cap bolts by uniformly tightening the bolts in the sequence shown in the illustration.

ПРИМЕЧАНИЕ:

Be careful not to deform the oil delivery pipe LH when tightening the bearing cap bolts.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}for 1 to 16

25 Н*м{255 кгс*см, 18 фунт-сила-футов}for 17 to 20

Tighten the 2 union bolts.

ПРИМЕЧАНИЕ:

Be careful not to deform the oil delivery pipe when tightening the union bolt.

Момент затяжки:

17 Н*м{173 кгс*см, 13 фунт-сила-футов}

Install the crankshaft timing sprocket and oil pump drive gear.

Set the No. 2 camshaft and crankshaft to TDC.

1. Turn the No. 2 camshaft to set the straight pin to the position shown in the illustration.
   

2. Turn the crankshaft timing sprocket in the opposite direction of the engine revolution direction to set the timing mark to the position shown in the illustration.
   

Align one of the chain's paint marks with the timing mark of the camshaft timing sprocket, and set that part of the chain to the camshaft timing sprocket.

УКАЗАНИЕ:

Do not set the camshaft timing sprocket to the cylinder head yet.

Align the chain's other paint mark to the crankshaft timing sprocket, and set that part of the chain to the crankshaft timing sprocket. Then install the camshaft timing sprocket (together with the remainder of the chain) onto the No. 2 camshaft's straight pin. Temporarily install the sprocket with the 4 bolts.

While holding the hexagon portion of the No. 2 camshaft, tighten the 4 bolts to install the camshaft timing sprocket to the No. 2 camshaft.

Момент затяжки:

20 Н*м{204 кгс*см, 15 фунт-сила-футов}

Install the vibration damper with the 2 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 15 фунт-сила-футов}

УКАЗАНИЕ:

Before installing the vibration damper, rotate the crankshaft counterclockwise to loosen the chain. After the installation, return the crankshaft to TDC.

Install the tensioner slipper.

Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner (*1).

Move the stopper plate downward to set the lock, and insert SST into the stopper plate hole (*2).

SST

09240-00020(09242-00250)

Install the chain tensioner with the 2 bolts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Remove SST.

Rotate the crankshaft pulley approximately 720°.

Check that the sprockets' timing marks are at No. 1 cylinder TDC, as shown the illustration.
If not, remove the chain and reinstall it.

Apply MP grease to a new oil seal lip.

ПРИМЕЧАНИЕ:

Keep the lip free of foreign objects.

Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump edge.

SST

09226-10010

ПРИМЕЧАНИЕ:

1. Do not tap the oil seal at an angle.
   
2. Wipe off extra grease on the crankshaft.
   

Install a new gasket and O-ring to the timing chain cover as shown in the illustration.

Apply seal packing to the timing chain cover as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Standard seal diameter:

Position	Specified Condition
A - A	2.0 to 4.0 mm (0.079 to 0.157 in.)
B - B	8.0 to 10.0 mm (0.315 to 0.394 in.)
C - C	Width: 13 mm (0.512 in.) Height: 6 mm (0.236 in.)

ПРИМЕЧАНИЕ:

1. Be sure to clean and degrease the contact surfaces, especially the 4 areas indicated by the arrows in the illustration.
   
2. When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   
3. When applying seal packing to area C - C, apply it in the direction of the white arrows in the illustration.
   
4. Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
5. Do not start the engine for at least 4 hours after installing.
   

Apply adhesive to the 4 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

УКАЗАНИЕ:

Bolt length: 37.5 mm (1.476 in.)

Temporarily install the timing chain cover with the 4 bolts.

Temporarily install a new seal washer and bolt A.

УКАЗАНИЕ:

Bolt length: 67.5 mm (2.657 in.)

Temporarily install the 8 bolts.

УКАЗАНИЕ:

Bolt length: 37.5 mm (1.476 in.)

Using several steps, tighten the 13 bolts.

Момент затяжки:

31.5 Н*м{321 кгс*см, 23 фунт-сила-футов}for except bolt A

21 Н*м{214 кгс*см, 15 фунт-сила-футов}for bolt A

Using a 10 mm socket hexagon wrench, install a new gasket and the timing chain cover tight plug.

Момент затяжки:

19 Н*м{194 кгс*см, 14 фунт-сила-футов}

Install a new gasket onto the timing chain cover as shown in the illustration.

Clean the 7 bolts and 7 bolt holes.

Apply adhesive to 2 or 3 threads of the bolt labeled A.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Temporarily install the water pump with the 7 bolts.

Standard bolt length:

Item	Specified Condition
Bolt A and C	45 mm (1.77 in.)
Bolt B	30 mm (1.18 in.)

Tighten the 2 bolts indicated by the arrows in the illustration. Then tighten the other bolts.

Момент затяжки:

32 Н*м{326 кгс*см, 24 фунт-сила-футов}

Align the keyway of the pulley with the key located on the crankshaft, then slide the pulley into place.

Using SST, install the pulley bolt.

SST

09213-58013
09330-00021

Момент затяжки:

250 Н*м{2549 кгс*см, 184 фунт-сила-футов}

Install a new O-ring and the oil strainer with the 3 bolts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}for bolt A and B

42 Н*м{428 кгс*см, 31 фунт-сила-футов}for bolt C

Install a new gasket and the oil filter bracket with the 4 bolts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Clean the inside of oil filter cap, threads, and O-ring groove.

Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap assembly.

Install a new oil filter element into the oil filter cap assembly.

Remove any dirt or foreign matter from the contact surfaces of the oil filter cap assembly (with oil filter element) and oil filter bracket.

Install the oil filter cap assembly (with oil filter element) to the oil filter bracket.

Using SST, tighten the oil filter cap.

SST

09228-06501

Момент затяжки:

40 Н*м{408 кгс*см, 30 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Check and clean the oil filter installation surface.

Apply seal packing in a continuous bead as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Standard seal diameter:

4.0 to 7.0 mm (0.157 to 0.276 in.)

ПРИМЕЧАНИЕ:

1. Remove any oil from the contact surfaces.
   
2. Install the oil pan within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not start the engine for at least 4 hours after installation.
   

Install the oil pan with the 18 bolts and 2 nuts.

Момент затяжки:

10.5 Н*м{107 кгс*см, 8 фунт-сила-футов}

Install a new gasket and the drain plug.

Момент затяжки:

38 Н*м{387 кгс*см, 28 фунт-сила-футов}

Install the level sensor with the 4 bolts.

Момент затяжки:

7.0 Н*м{71 кгс*см, 62 фунт-сила-дюймов}

Install the 4 nozzle holder clamp seats.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

Install the new nozzle seat to the cylinder head.

Install new O-rings to each injector.

Apply a light coat of engine oil to the O-rings on each injector.

Install the injectors to the cylinder head.

ПРИМЕЧАНИЕ:

Fit the injectors to the nozzle seats.

Install the nozzle holder clamp and washer as shown in the illustration.

Install the nozzle holder clamp bolts by hand.

ПРИМЕЧАНИЕ:

1. Pay attention to the mounting direction (beveled edge) of the washer.
   

1. When temporarily attaching the nozzle holder clamp and the mounting bolt, be careful not to position them at an angle.
   

УКАЗАНИЕ:

Apply a light coat of engine oil to the threads of the nozzle holder clamp bolts.

Temporarily install the No. 1, No. 2, No. 3 and No. 4 injection pipes.

Temporarily install 5 new gaskets, the leakage pipe, bolt and 5 union bolts.

Tighten the 4 nozzle holder clamp bolts.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

Remove the 4 injection pipes.

Tighten the 5 union bolts.

Момент затяжки:

(*1):

18 Н*м{183 кгс*см, 13 фунт-сила-футов}

(*2):

22 Н*м{224 кгс*см, 16 фунт-сила-футов}

Check that there are no leaks from the nozzle leakage pipe connection.

1. Install SST and gasket.
   

   SST

   09280-00010
   09268-45014
   (90405-06167)
   

   Момент затяжки:

   21 Н*м{214 кгс*см, 15 фунт-сила-футов}

2. Apply a light coat of soapy water (any fluid to detect fuel leakage) to the No. 2 nozzle leakage pipe connection.
   





3. Using SST (turbocharger pressure gauge), attach SST (turbocharger pressure gauge) to the fuel return side of SST (union), and maintain 100 kPa (1.0 kgf/cm², 14.5 psi) of pressure for 60 seconds to check that there are no bubbles from the pipe connection.
   

   SST

   09992-00242
   

4. After checking for fuel leaks, wipe off soapy water from the pipe connection.
   

5. Remove SST and gasket.
   

Remove any old seal packing material.

Apply seal packing to the cylinder head as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Standard seal diameter:

6 mm (0.24 in.)

Install the gasket to the cylinder head cover.

Install the cylinder head cover with the 12 bolts, 2 nuts and 2 washers.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

ПРИМЕЧАНИЕ:

1. When installing the cylinder head cover to the cylinder head, do not allow the injectors to damage the nozzle holder gasket.
   
2. Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   

УКАЗАНИЕ:

Uniformly tighten the bolts and nuts in several passes.

Install the 4 nozzle holder seals.

ПРИМЕЧАНИЕ:

Apply a light coat of silicone oil to the nozzle holder seal side.

Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head.

Maximum warpage:

0.40 mm (0.0157 in.)

Install the exhaust manifold and gasket.

Loosely install the 2 collars of the exhaust manifold with the nuts labeled A. Tighten the nuts until the contact surface of the exhaust manifold contacts the cylinder head.

Loosely install the 6 collars with the 6 nuts.

УКАЗАНИЕ:

1. When installing the collars, pay attention to the mounting orientation. The ring groove of the collar should be on the outside. Refer to the illustration.
   
2. Tighten the nuts so that the position of the exhaust manifold can be adjusted in a later step.
   

Install a new gasket and the turbocharger with the 3 nuts.

Момент затяжки:

60 Н*м{612 кгс*см, 44 фунт-сила-футов}

Install the turbocharger stay with the 2 spacers and 2 nuts.

Момент затяжки:

36 Н*м{367 кгс*см, 27 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Do not reuse the turbocharger stay.

Tighten the 8 nuts.

Момент затяжки:

47 Н*м{479 кгс*см, 35 фунт-сила-футов}

Install 2 new gaskets and the turbo oil pipe with the 2 bolts.

Момент затяжки:

35 Н*м{357 кгс*см, 26 фунт-сила-футов}

Install 2 new gaskets and a new O-ring to the EGR cooler.

Temporarily install the EGR cooler with the 2 bolts and 2 nuts.

Temporarily install the 4 bolts.

Tighten the 2 bolts and 2 nuts holding the EGR cooler to the cylinder block.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

Tighten the 2 bolts holding the EGR cooler to the exhaust manifold.

Момент затяжки:

16 Н*м{163 кгс*см, 12 фунт-сила-футов}

Tighten the 2 bolts holding the EGR cooler to the cylinder head.

Момент затяжки:

24 Н*м{245 кгс*см, 18 фунт-сила-футов}

Install a new O-ring to the EGR cooler.

Temporarily install the No. 2 EGR valve assembly, No. 1 EGR pipe, 2 new gaskets, 2 bolts and 2 nuts to the EGR cooler.

Install a new gasket to the No. 1 EGR pipe.

Install a new gasket to the EGR cooler.

Temporarily install the EGR cooler assembly with the 2 bolts and 2 nuts (^*1).

Temporarily install the 4 bolts (^*2).

Tighten the 2 bolts and 2 nuts.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

Tighten the 2 bolts to the exhaust manifold.

Момент затяжки:

16 Н*м{163 кгс*см, 12 фунт-сила-футов}

Tighten the 2 bolts to the cylinder head.

Момент затяжки:

24 Н*м{245 кгс*см, 18 фунт-сила-футов}

Tighten the 2 bolts and 2 nuts.

Момент затяжки:

21 Н*м{241 кгс*см, 15 фунт-сила-футов}

Connect the vacuum hose.

Temporarily install a new gasket and the exhaust manifold converter with the 3 nuts.

Temporarily install the No. 2 exhaust manifold stay with the nut and 2 bolts.

Temporarily install the No. 2 manifold stay with the 3 bolts.

Temporarily install the No. 1 manifold stay with the bolt and nut.

Tighten the 2 bolts holding the No. 2 exhaust manifold stay to the cylinder block (upper bolt → lower bolt).

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

While pushing the manifold converter towards the turbocharger, tighten the 3 nuts holding the exhaust manifold converter to the turbocharger.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

Tighten the nut holding the No. 2 exhaust manifold stay to the exhaust manifold converter.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

Tighten the bolt holding the No. 2 manifold stay to the exhaust manifold converter.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

УКАЗАНИЕ:

Ensure that the stay is pushed flush with the cylinder block and manifold converter while tightening.

Tighten the 2 bolts holding the No. 2 manifold stay to the cylinder block.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

Tighten the bolt holding the No. 1 manifold stay to the cylinder head.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

УКАЗАНИЕ:

Ensure that the stay is pushed flush with the cylinder head and manifold converter while tightening.

Tighten the nut holding the No. 1 manifold stay to the exhaust manifold converter.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

Temporarily install a new turbine outlet elbow gasket and exhaust manifold converter with the 3 nuts.

Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.

Temporarily install the No. 2 manifold stay with the 3 bolts.

Temporarily install the No. 1 manifold stay with the bolt and nut.

Tighten the 2 bolts of the No. 2 exhaust manifold stay to the cylinder block (Upper bolt → Lower bolt).

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

Tighten the 3 nuts of the exhaust manifold converter to the turbocharger sub-assembly (While pushing the manifold converter towards the turbocharger sub-assembly).

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

Tighten the nut of the No. 2 exhaust manifold stay to the exhaust manifold converter.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

Tighten the bolt of the No. 2 manifold stay to the exhaust manifold converter.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

УКАЗАНИЕ:

Ensure that the stay is pushed flush with the cylinder block and manifold converter while tightening.

Tighten the 2 bolts of the No. 2 manifold stay to the cylinder block.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

Tighten the bolt of the No. 1 manifold stay to the cylinder head.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

УКАЗАНИЕ:

Ensure that the stay is pushed flush with the cylinder head and manifold converter while tightening.

Tighten the nut of the No. 1 manifold stay to the exhaust manifold converter.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

Install the 4 glow plugs.

Момент затяжки:

12.3 Н*м{125 кгс*см, 9 фунт-сила-футов}

Install the glow plug connector with the 4 nuts.

Момент затяжки:

2.2 Н*м{22 кгс*см, 19 фунт-сила-дюймов}

Install the wire harness with the nut (A).

Момент затяжки:

4.0 Н*м{41 кгс*см, 35 фунт-сила-дюймов}

Install the 5 grommets.

Install a new gasket and the inlet housing with the 3 nuts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Using needle-nose pliers, grip the claws of the 2 clips and slide the 2 clips to install the No. 4 water by-pass hose.

Apply soapy water to a new O-ring and install it to the by-pass pipe.

Install the by-pass pipe to the inlet housing with the 2 bolts.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

Apply a light coat of engine oil to 2 new O-rings.

ПРИМЕЧАНИЕ:

Do not apply engine oil to the new O-ring labeled A.

Install the 3 O-rings to the oil cooler bracket.

Install the oil cooler bracket with the 6 bolts and nut.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

УКАЗАНИЕ:

Bolt length: 36 mm (1.42 in.) for bolt A

Bolt length: 49 mm (1.93 in.) for except bolt A

Install the oil pipe and 2 new gaskets with the 2 union bolts.

Момент затяжки:

35 Н*м{357 кгс*см, 26 фунт-сила-футов}

УКАЗАНИЕ:

Be sure to install the union bolt A so that the gasket is positioned as shown in the illustration.

Apply soapy water to a new O-ring and install it to the by-pass pipe.

Install the by-pass pipe with the 2 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 15 фунт-сила-футов}

Apply a light coat of engine oil to 2 new O-rings.

ПРИМЕЧАНИЕ:

Do not apply engine oil to the new O-ring labeled A.

Install the 2 O-rings and the new O-ring labeled A to the oil cooler bracket.

Install the oil cooler with the 5 bolts.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

Connect the oil pressure switch connector.

Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head.

Maximum warpage:

0.10 mm (0.0039 in.)

Install a new gasket and the intake manifold with the 7 bolts and 2 nuts.

Момент затяжки:

26 Н*м{265 кгс*см, 19 фунт-сила-футов}

Install a new gasket and the diesel throttle body with the 2 nuts and 2 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 15 фунт-сила-футов}

Connect the throttle position sensor connector.

Connect the throttle motor connector.

Install the common rail assembly with the 2 bolts.

Момент затяжки:

21 Н*м{209 кгс*см, 15 фунт-сила-футов}

Using pliers, slide the clip to connect the No. 4 fuel hose.

Install the cover bracket with the 2 bolts.

Момент затяжки:

20 Н*м{204 кгс*см, 15 фунт-сила-футов}

Install the pressure sensor with the bolt.

Момент затяжки:

8.8 Н*м{90 кгс*см, 78 фунт-сила-дюймов}

Install a new gasket and the EGR valve with the 2 bolts.

Момент затяжки:

24 Н*м{245 кгс*см, 18 фунт-сила-футов}

Connect the EGR valve connector.

Temporarily install 2 new gaskets and the No. 2 EGR pipe with the nut and bolt as shown in the illustration.

Temporarily install the bolt and nut as shown in the illustration.

Tighten the 2 bolts holding the EGR pipe to the cylinder head.

Момент затяжки:

24 Н*м{245 кгс*см, 18 фунт-сила-футов}

Tighten the 2 nuts holding the EGR pipe to the EGR valve.

Момент затяжки:

24 Н*м{245 кгс*см, 18 фунт-сила-футов}

Install a new O-ring to the dipstick guide.

Install the dipstick guide with the 2 bolts.

Момент затяжки:

33 Н*м{337 кгс*см, 24 фунт-сила-футов}

Install a new O-ring to the supply pump assembly.

Install the supply pump drive coupling.

ПРИМЕЧАНИЕ:

When reusing the coupling, install the coupling in the same orientation (top/bottom, front/back) as when it was removed.

УКАЗАНИЕ:

Line up the coupling with the groove in the camshaft end.

Install the supply pump assembly and the 2 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 15 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Apply the engine oil to the O-ring of the supply pump assembly.

УКАЗАНИЕ:

Remember the orientation of the supply pump drive coupling when removing the supply pump from the cylinder head.

Connect the suction control valve assembly.

Connect the fuel temperature sensor connector.

Install a new gasket, exhaust fuel addition injector and nozzle holder clamp with the washer and bolt.

Момент затяжки:

29 Н*м{296 кгс*см, 21 фунт-сила-футов}

УКАЗАНИЕ:

Install the nozzle holder clamp while holding it.

Install the fuel tube sub-assembly and a new gasket with the union bolt.

Момент затяжки:

23 Н*м{235 кгс*см, 17 фунт-сила-футов}

Turn the retainer in the direction indicated by the arrow until the retainer stops.

Insert the fuel tube connector into the injector.

Turn the retainer in the direction indicated by the arrow until it makes a "click" sound.

ПРИМЕЧАНИЕ:

If the fuel tube connector is not inserted to the correct position of the injector, the retainer cannot be turned further in the direction of the arrow.

Connect the exhaust fuel addition injector connector.

Install the No. 2 nozzle leakage pipe, gasket and 2 bolts.

Момент затяжки:

32 Н*м{321 кгс*см, 23 фунт-сила-футов}

Using pliers, grip the claws of the 3 clips and slide the 3 clips to connect the 3 fuel hoses.

Temporarily install the 4 injection pipes.

Using SST, tighten the nut at the common rail end of the injection pipe.

SST

09023-38401

Момент затяжки:

without SST:

30 Н*м{306 кгс*см, 22 фунт-сила-футов}

with SST:

27 Н*м{275 кгс*см, 20 фунт-сила-футов}

УКАЗАНИЕ:

1. Use of proper SST is necessary to ensure that the correct torque is applied to the injection pipe nut.
   
2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
   
3. Make sure that the pipe is not deformed or twisted during installation.
   If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new one.
   

Using SST, tighten the nut at the injector end of the injection pipe.

SST

09023-12701

Момент затяжки:

without SST:

34 Н*м{347 кгс*см, 25 фунт-сила-футов}

with SST:

31 Н*м{316 кгс*см, 23 фунт-сила-футов}

УКАЗАНИЕ:

1. Use of proper SST is necessary to ensure that the correct torque is applied to the injection pipe nut.
   
2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
   
3. Make sure that the pipe is not deformed or twisted during installation.
   If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new one.
   

Apply a light coat of engine oil to the O-ring of the sensor.

Install the sensor with the bolt.

Момент затяжки:

8.8 Н*м{90 кгс*см, 78 фунт-сила-дюймов}

Connect the sensor connector.

Install the vacuum pump assembly for 1AD-FTV (See page Нажмите здесь).

Install the tensioner with the 3 bolts.

Момент затяжки:

20 Н*м{204 кгс*см, 15 фунт-сила-футов}

ПРИМЕЧАНИЕ:

As the bolts' heads are not as thick as typical bolts, be careful not to damage them during installation.

Set the mounting bracket.

Temporarily tighten the 2 bolts (B) and 2 nuts.

Tighten the 2 bolts (A).

Момент затяжки:

28 Н*м{286 кгс*см, 21 фунт-сила-футов}for bolt A

Tighten the 2 bolts (B) and 2 nuts.

Момент затяжки:

80 Н*м{816 кгс*см, 59 фунт-сила-футов}for bolt B

Apply soapy water to a new O-ring and install it to the by-pass pipe.

Install the No. 4 water by-pass pipe with the bolt.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

Install the idler pulley with the bolt.

Момент затяжки:

40 Н*м{408 кгс*см, 30 фунт-сила-футов}

Install the idler pulley cover plate.

Install the idler pulley with the bolt.

Момент затяжки:

40 Н*м{408 кгс*см, 30 фунт-сила-футов}

Apply a light coat of engine oil to the O-ring of the sensor.

Install the sensor with the bolt.

Момент затяжки:

8.8 Н*м{90 кгс*см, 78 фунт-сила-дюймов}

Connect the sensor wire harness clamp.

Connect the sensor connector to the bracket.

Connect the sensor connector.

Install the generator assembly with the 3 bolts.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Make sure that the wire harness of the crankshaft position sensor does not get caught between the cylinder block and the generator assembly when installing the generator assembly.

Connect the generator wire to terminal B with the nut and bolt.

Момент затяжки:

for Nut:

9.8 Н*м{100 кгс*см, 87 фунт-сила-дюймов}

for Bolt:

7.7 Н*м{79 кгс*см, 68 фунт-сила-дюймов}

Install the terminal cap.

Connect the generator connector.

Install the sling device and chain block to the engine and hang the engine.

Remove the engine stand.

Hold the crankshaft with SST.

SST

09213-58013
09330-00021

Using several steps, install and tighten 8 new bolts with a T55 "TORX" socket wrench uniformly in the sequence shown in the illustration.

Момент затяжки:

71 Н*м{724 кгс*см, 52 фунт-сила-футов}

ПРИМЕЧАНИЕ:

1. Do not reuse the flywheel installation bolts.
   
2. Be sure to check the tightening torque within 5 minutes after tightening.
   
3. Do not impact or damage the flywheel installation bolts. Be sure to handle them carefully.
   
4. Make sure there is no oil on the bolts.
   

УКАЗАНИЕ:

Make sure that the seating surface of the flywheel installation bolts and the installation surfaces of the crankshaft and flywheel are free from oil or foreign matter.

Install the clutch disk assembly for EA61 (See page Нажмите здесь).

Install the clutch cover assembly for EA61 (See page Нажмите здесь).

Inspect and adjust clutch cover assembly for EA61 (See page Нажмите здесь).

Install the manual transaxle assembly for EA61 (See page Нажмите здесь).

Install the stiffener plate LH for EA61 (See page Нажмите здесь).

Install the stiffener plate RH for EA61 (See page Нажмите здесь).

Install the oil pan insulator for EA61 (See page Нажмите здесь).

Install the front engine mounting bracket for EA61 (See page Нажмите здесь).

Install the rear engine mounting bracket for EA61 (See page Нажмите здесь).

Install the starter assembly with the 2 bolts.

Момент затяжки:

64 Н*м{653 кгс*см, 47 фунт-сила-футов}

Install the wire harness with the nut.

Момент затяжки:

9.8 Н*м{100 кгс*см, 87 фунт-сила-дюймов}

Connect the starter connector.

Install the bracket with the bolt.

Момент затяжки:

26 Н*м{260 кгс*см, 19 фунт-сила-футов}

Install the ground cables to the manual transaxle with the 2 bolts.

Момент затяжки:

8.4 Н*м{85 кгс*см, 74 фунт-сила-дюймов}

Install the No. 1 air tube for EA61 (See page Нажмите здесь).

Install the engine wire to the engine.

С помощью SST снимите передний приводной вал.

SST

09520-00031
09520-01010

ПРИМЕЧАНИЕ:

1. Будьте осторожны, чтобы не повредить сальник картера трансмиссии в блоке с главной передачей, чехол внутреннего шарнира и пылезащитный чехол приводного вала.
   
2. Старайтесь не уронить приводной вал.
   

Выверните 2 болта и вытяните приводной вал вместе с корпусом подшипника вала.

Снимите приводной вал с трансмиссии в блоке с главной передачей.

ПРИМЕЧАНИЕ:

1. Будьте осторожны, чтобы не повредить чехол внутреннего шарнира и пыльник приводного вала.
   
2. Старайтесь не уронить приводной вал.
   

Install the bolt which secures the engine mounting bracket to the mounting insulator.

Момент затяжки:

95 Н*м{969 кгс*см, 70 фунт-сила-футов}